Fiberset delivers high quality fabrication and production of advanced composite structures for customers in aerospace, government and industry.
We are fast on our feet and flexible to meet your needs, providing innovative solutions and uncompromising products from concept to full-scale production. For nearly 30 years, our customers have enjoyed personalized service, rapid response and competitive pricing.
Our services include customized fiberglass for highly unique requirements to industrial fiberglass for large-scale production runs. We also provide close tolerance, sophisticated composite structures and components, including engineering support, product modification, and repair services.
Based in the Mojave Air and Space Port, we truly can see the future for fiberglass and composite products. At Fiberset, we deliver what you need.

After one and one-half years of in-house research and development, Fiberset is proud to announce its first long-term contract for homeland security. This contract has enabled us to purchase our two autoclaves for this production. Due to the nature of this classified project, we can only comment on how excited we are to be a part of protecting the lives of those who protect us.

Project Name: Baby "Godzilla" Movie Head

Customer:Patrick Tatopoulos Design Inc

When Fiberset was selected by Patrick Tatopoulos Design, Inc. to manufacture the baby head animatronics infrastructure for the hit movie film "Godzilla", the whole region was filled with excitement. Tatopoulos provided the head design, but their team was having trouble with the actual development of the part and time was a critical factor. Fiberset's innovative team of experienced technicians suggested the use of carbon fiber with a beautiful epoxy resin finish, which provided the properties the design team needed. The prop masters were very satisfied when they gained twice the strength and half the weight of their original material of choice plus getting the parts on time. Since these were actually worn by stunt people, the finished part properties were just what they needed to shoot the scenes. If you haven't seen the movie yet, we suggest you do.

Project Name: King's Crown

Customer:IGT Inc

The "King's Crown", once the largest slot machine in the world, now resides at the King's Casino in Heritage Bay, St John's, Antigua. The crown was designed and fabricated by Fiberset for IGT, the world leader in gaming machines. The crown (~15 ft. in diameter) was made from urethane foam and glass mat outer skin, with a matte, velvet-like finish and exquisite detail to resemble a pineapple. The vibrant colors are still true today as hundreds of fortune seekers gaze at the detail and size of this magnificent piece of work.

Project Name: Panelite LLC Panels

Fiberset has had the opportunity to fabricate and manufacture the panels used for Panelite LLC. Fiberset uses a sandwich construction technique typically exploited in the aerospace industry for its high strength to weight ratio and excellent resistance to deflection. The structural honeycomb core provides strength and consistent rigidity at a very low density: when bonded to similarly lightweight facings, every honeycomb cell wall acts like the web of an I-beam, forming an extremely strong, stiff yet lightweight composite panels. Fiberset has met Panelite's rigorous delivery schedule on time every time.

Project Name: Magic Mountain

Magic Mountain has continually contracted Fiberset to manufacture and repair several of their amusement park rides on an regular basis.

Project Name:
Wind Energy

When Fiberset opened its doors in Mojave, the wind energy industry was enjoying a growth spurt due to investment tax credits. The hills of Tehachapi, California were soon covered with hundreds and then thousands of wind turbines. A large portion of these machines, complete with composite blades up to seventy feet long, were imported from Europe. Once the local turbine operators learned about Fiberset and our wide range of composite skills, they began to call on us for repairs and consulting to save themselves the cost of flying in a factory representative from Europe.

Fiberset designed a tough, low-cost 340-piece acid containment system to retrofit various-sized racks of industrial batteries, keeping batteries accessible for maintenance. The plan used tough inexpensive materials and simple standardized components in conjunction with an adjustable 30 piece tooling design

Project Name:
US Borax

We performed repairs on an 80’ diameter, 14-piece sectional lid at the US Borax facility. In cold weather, thermal reflectors are fabricated using foil-backed celotex to reflect the sun onto the parts and heat the repair area. Additional large-scale improvements are continuing at this facility.

Project Name:
Channel Covers

Customer:Hoover Dam

This is a good example of increasing the life expectancy of a product by taking advantage of the properties of composites, in this case corrosion resistance. These covers are for channels in the walls of the caracole stairways used for service access inside the dam. They provide a waterproof seal to prevent water from splashing onto the nearby staircases caused by normal seepage through the concrete.

Fiberset was selected to develop and manufacture this hand-crafted monocoque bicycle made of DuPont Kevlar fiber for Stephen & Sharp Design Group. The lightness (~ 4lbs), strength, and comfortable ride of the frame made this bike a sure winner in combination with experienced racer, Inga Thompson. Fiberset excels at producing articles that are necessary for that high performance competitive edge.

Project Name:
Auto Racing

Fiberset has had the opportunity to manufacture a variety of custom racing parts for numerous classes, like this Tiga Sports 2000 nose cone for Karl Luft Racing Ind. More recently, Fiberset has been working with NASCAR team to develop a new product. These high performance parts are hand crafted by highly skilled composite technicians to improve aerodynamic properties under stringent tolerances, while decreasing weight. The Goal - Faster is Better!

Project Name: Ski Helmet

Customer:Abromowitz & Assoc.

Fiberset fabricated a master pattern of a downhill racing ski helmet, tooling, and final parts for Abromowitz & Associates. High performance properties mixed with the need for improved impact and abrasion resistance properties led to the decision to use aramid as the primary fiber. Working under stringent tolerances, Fiberset produced an exceptional product like no other on the market

Project Name:
Custom Kayaks

Customer:R. Thompson

Made from carbon fiber, aramid, veneer, and foamcore, these kayaks were handcrafted to resemble the antique kayaks from the earlier part of the 20th Century. By blending the technology of today with the natural appeal of a real wood lining and deck, Fiberset produced a beautiful leisure craft for the naturalist at heart. Detailed contouring and the treated wood panels added special qualities, performance, and value to this watercraft.

Fiberset was selected to fabricate two proofs of concept inlet rakes for the GE F 404 engine for the high alpha F-18 aircraft. The purpose was to provide concepts to be environmentally tested. The fabrication consisted of three major pieces made from plies of carbon fiber cloth with a gel-coat quality finish. The contractor required completion within two weeks of receipt of order. The prototypes were delivered on schedule.

Project Name:
NF-111A AFTI Gloves

Customer: NASA Dryden FRC

Fiberset was selected to fabricate and install “gloves” on both wings of an F-111 airplane to study the applicability of supercritical natural laminar flow airfoils. The project included fabrication and installation of a “mirror section” airfoil glove on the left wing for aircraft symmetry and “area fill” gloves to the upper surfaces of both inboard wings to correct wing pressure distribution for operation of the NLF airfoil section. In addition, we identified and demonstrated the use of a method by which the gloves were to be removed from the F-111 wings without damage to the aircraft itself.

Project Name:
Retainer rings

Customer: Tracor Flight Systems (MARCONI)

Fiberset was selected to manufacture a retainer ring for the MQM Missile drone. This retainer ring cast out of urethane holds an inflatable seal that protects internal systems from water penetration from the environment. A couple hundred have been manufactured to date as the project continues. Tracor FSI has recently been purchased by MARCONI. We welcome MARCONI to Fiberset’s list of satisfied customers.

Project Name:
BAE Ski Program

Sub contracted by BAE (previously Tracor and Marconi), Fiberset was asked to supply the U.S. Coast Guard with improved skis for their HH-65A Dolphin short range recovery helicopters. These three-piece ski sets are meant to allow glacier/snow field landings, however the originals did not stand up to the test. Improving the ruggedness without increasing the weight was quite a challenge.
This job required the creation of new tooling that would be used in the fabrication and assembly of the skis. Several lamination schedules were tested to ensure that the structural properties of the improved skis would exceed Coast Guard requirements. The skis are composed of carbon fiber, Kevlar, and fiberglass in an epoxy matrix. Areas needing additional stiffness are cored with Nomex Honeycomb. Hard points are bonded in prior to joining the upper and lower halves, and the finished skis are post cured to 260 F.

Project Name:
DC-8 End and Center Fairings

End fairings and center fairings were manufactured to hold a 21/37 GHz radiometer. The existing fairings were splashed for a quick inexpensive tooling. These parts were fabricated for NASA supporting the Airborne Science Project (AMMR fairing project).

Project Name:
Thick Wing Delta Water Tunnel Model

Customer: NASA Dryden FRC

Fiberset was selected to fabricate a complex Flow Visualization System (FVS) water tunnel model. This model designated as the “Thick Wing Delta” (TWD) was tested in the FVS with the results compared and added to the existing analytical and wind tunnel database. The fabrication process consisted of building up a small plastic model of the Thick Wing Delta aircraft. What made this project unique was the need for two sets of leading edge wings for the model. The first set was the baseline configuration leading edges, and the second set had vortex flaps. Both sets of leading edges needed to be interchangeable on the model. In addition, installation of 20 fine stainless steel tubes (~1/32” OD) in the waterproof model was necessary for adequate flow field visualization.

Project Name:
X-38 Master Pattern & Tooling

Customer: NASA Johnson

The International Space Station Emergency Crew Return Vehicle was originally designed to hold four astronauts. Fiberset completed the master pattern and the fourteen piece tooling set shortly before NASA redesigned the craft to hold six people. The changes resulted in major rework of the upper half of the master pattern and all new tooling for the areas affected. Laser tracking was performed by NASA to verify that dimensions and symmetry were within tolerance. Fiberset received a rating of “Excellent” in Quality of Product or Service category by NASA Johnson Space Center in May 1999 for this program.

Project Name:
Camera Housing

Customer: SVS R&D Systems Inc.

This proof of concept (surrogate) and final part was fabricated for SVS Systems Inc., Albuquerque, NM. The challenge to this complex unit was in fabricating several components with a variety of processes, cuts, and shapes that would later need to mesh together. The gambling sphere (~37" dia.) mounts via an extension arm laterally to the outside of a helicopter for aerial camera recording. Its purpose was to replace an old, manual, and dangerous method of inspecting high power transmission lines in remote areas. It holds an array of cameras including infrared that communicate with an innovative software package on board. The unit records GPS data, real time date recording and stamping, as well as images & video of the lines and transistors.

Project Name:
F-18 HARV Camera Mount and Housing

Customer: NASA Dryden

In support of the Laser Light Sheet Experiment, Fiberset fabricated a base plate from splashes made off existing aircraft fuselage panels and a removable camera housing. This housing, mounted on top of the fuselage, just ahead of the vertical fins, required precise camera positioning and an optically sound clear vision panel.

Project Name:
T-33 Camera Housing

Customer: Honda R&D

An infrared video camera was mounted on the bottom of this T-33 to document the extent of any laminar flow achieved on a full span upper and lower surface wing gloves fabricated by Fiberset. The size and location of the camera required a fairing over six feet in length in order to fair in and mount properly.

Project Name:
X-29-049 Camera Housings

Customer:NASA Ames/Dryden

In preparation of high angle of attack flows visualization research on the X-29, engineers decided to mount two cameras on the aircraft. One would be located at the base of the vertical stabilizer and the other on the right wing tip. Fiberset was selected to fabricate the camera mounts and housings. These parts were manufactured to perform at a maximum allowable dynamic pressure of 550 psf and 150 degrees Fahrenheit. The camera housing on the vertical fin was designed to be easily removable allowing routine access to the camera.

Founded almost 30 years ago, Fiberset’s strength lies in our ability to deliver uncompromising products from concept to full-scale production. We are leaders in creating and developing fiberglass parts. From industrial fiberglass in large production runs to custom fiberglass for unique requirements, we take your vision to reality. Located in a HUB Zone with our 8(a) application in the works, we are our industry’s only Woman-Owned Small Business whose sole focus in on you, our client. As your one-stop, composite shop for everything fiberglass, we believe that each and every project is a reflection on us and we insist on the highest possible standards. Based in the Mojave Air and Space Port, we truly can see the future for fiberglass and composite products from here. Plenty of companies will give you what they have. At Fiberset, we deliver what you need.

Company Overview

Fiberset Incorporated is a quality leader in the design, fabrication and production
of advanced composite structures. For more than 22 years, Fiberset has delivered
the close tolerance, sophisticated composite structures and components required
by its customers in aerospace, government and industry. Fiberset became a leader
in the composites industry by delivering products and logistics support of the
highest quality, plus related engineering, modification, and repair services.
Fiberset’s list of satisfied customers includes U.S. Government / Department of
Defense agencies and defense contractors, as well as diversified commercial and
industrial companies.

Awards & Recognition

Award-winning, woman-owned Fiberset built its professional reputation on performance born of
dedication to customer service, agility, employee training, and rapid implementation of emerging
materials, processes and technologies in the composites industry. We were rewarded the NASA
Woman- Owned Small Business of the Year award in 1999.

Fiberset is proud to have made significant contributions to many of the nation’s cutting edge projects in
aerospace research and industrial and commercial product development. Kern County awarded Fiberset
the 2000 Outstanding Small Business Award in recognition of Fiberset’s significant contribution to Kern
County economic development.

Our People

We have combined the strengths of several talented, experienced individuals to create a synergistic
team with a goal to meet or exceed the customer's expectations at every project level. The end result is
a satisfied customer, repeat business, and a professional referral.

Fiberset personnel are of the highest caliber and their expertise is reflected in the quality of work.
Working with carbon, Kevlar or fiberglass, as well as other exotic materials, processes and finishes,
Fiberset specialists fabricate top quality components with expert care and attention to detail.

Quality Assurance

Fiberset is ISO 9000 / AS 9100 compliant.

Consistent quality and dependable delivery from Fiberset are recognized in numerous awards for technical and management achievement. Fiberset was honored as NASA Dryden Flight Research Center’s Woman-Owned Small Business of the Year for 1999 - 2000. Additionally, Fiberset received a rating of “Excellent” in Quality of Product or Service category from NASA Johnson Space Center.

Location & Facilities

Fiberset occupies 17,340 square feet in four separate facilities including flight line access. The recent acquisition of new market contracts is expanding our operation to include 16,000 square feet of additional manufacturing facilities as well as acquiring additional autoclaves. Strategically located in Southern California at the Mojave Air and Spaceport, Fiberset has direct access to Interstate highway, air and rail transport for most any size structure.

Equipment List

Compressed air (Plumbed and portable)

Vacuum (Plumbed and portable)

Climate control (All facilities)

Controlled material storage (All Facilities)

Freezers – Portable

Calibrated inspection equipment

Laser and visual transits

Video and still documentation capabilities

Dust containment / evacuation (All Facilities)

Oven - 6’ x 8’ Up to 300F-Recording capabilities

Oven - 3’ x 4’ Up to 1200F-Recording capabilities

Autoclave - 5' x 10' 450F 100 PSI

Rockwell vertical mill

Lagun FTV-4 Vertical mill – NC

Forklift

Band saws

Drill presses

Belt/disc sanders

Welding capabilities – Wire feed, arc, and gas

Sand blasters – Large and small

Bench and hand tools, electric and pneumatic

Computer stations – 13 fixed, 2 portable

Computers on LAN – 9

CAD/Solidworks capable

Careers

Here at Fiberset, our people are our greatest asset. We have ongoing recruitment for talented and
experienced composite technicians and engineers. We require a minimum of one year experience or
equivalent education in building, repairing or finishing with Fiber Reinforced Plastics such as fiberglass,
carbon fiber and Kevlar, plus applications of advanced resin systems and coatings. Please note that only
applications from US Citizens can be considered. Fiberset is an equal opportunity employer.

Fiberset has ongoing programs to recruit, train and retain the best-qualified people at every position. Our participation in a federally funded Department of Labor Displaced Aerospace Worker Grant enabled employees in their first quarter of employment to complete a 499-hour on-the-job training program that advanced their skills. The company’s retention program is successful, with average annual attrition under 10%.

Fiberset put its years of expertise and experience in "Laminar Flow" technology to use in preparing a feasibility study for a proposed "Glove" installation on the SR-71A Research Aircraft. The primary focus of this study was to investigate the feasibility a "glove" installation. Other aircraft issues such as aerodynamics, stability and control, and structural dynamics were considered in this study as it related to the glove installation. The glove installation would be required to withstand over 50 hours of flight testing, speeds of up to Mach 1.7, and dynamic pressures of up to 686 psf.

Project Name: DC-10 Fuselage Fairings

Customer: Raytheon Flight Test Operations

Large-scale prepreg and honeycomb fairings were built in support of the airborne missile-tracking program. Fiberset also built a composite
ram air fairing that is part of a super-cooling system used to prevent optics from fogging up when exposed to high altitude temperatures.

Project Name: A-300 Engine Nacelle

Customer: General Electric

Fiberset was contracted for the contouring work on an Airbus A-300 engine nacelle. GE was having difficulty achieving laminar flow and wanted to reduce drag .05% to aid in fuel efficiency. The Fiberset composite field technicians performed all the necessary precision contouring
on the forward part of the engine nacelle to meet critical client requirements. Using infrared cameras, surface static ports, and surface hot films, GE finally met their goal and verified laminar flow and reduced drag.

Project Name:DC-8 Fuselage Fairings

Customer: NASA
Dryden
Fairings were manufactured to streamline a 21/37 GHz radiometer. These parts were fabricated in support of the Airborne Science Project. This DC-8 is used to conduct research activities including storm and hurricane observations and has been extensively modified to perform as a flying laboratory.

Project Name: ER-2 Modifications

Customer: NASA Dryden

Several flight articles have been repaired, remanufactured, or modified by Fiberset to enhance the
high altitude performance and research collection capabilities. These parts have included nose cones,
magnetic flux housings, hatch covers, fairings, radomes, and tail cones. The mission of these high
altitude aircraft is to advance understanding of the total Earth system and the effects of human-induced
changes on the global environment (“Mission to Planet Earth”).

Project Name: T-33 Laminar Flow Wing Gloves

Customer: Honda R&D

Fiberset was sought out on the recommendation from NASA engineers to assist Honda in their early
development stages of the now highly publicized about HondaJet. While working at the job site of
AVTEL Aircraft Services, Fiberset was contracted by Honda R&D to fabricate on the wings of a T-33
aircraft Laminar Flow Wing Gloves. The contract ran for one year as Fiberset technicians diligently
worked through weekends and holidays to meet Honda's stringent flight schedule. Fiberset also
provided the on-site support of dozens of flight tests, modifying the "gloves" as necessary to help Honda
achieve the desired test results.

Project Name: NASA F-16XL Wing Gloves (Ship 1 & 2)

Customer: NASA Dryden

Constructing “Wing Gloves” for aerodynamic studies is a unique specialty of ours. We have worked
on virtually dozens of aircraft to help push the flight envelope boundaries and gather information to
be used in the future design of high speed aircraft. Projects ranged from simple shape changes to fully
instrumented test sections required to fair in active suction titanium inserts. In many cases, when the
test program was completed the aircraft would be returned to original configuration. Fiberset was
able to develop an installation process allowing for the rapid, clean removal of the aerodynamic mod,
thus saving time and money for the customer. Fiberset received a Group Achievement Award for the
Supersonic Laminar Flow Control Experiments from NASA.

Project Name: F-104 Flight Test Fixture

Customer: NASA Ames/Dryden

NASA originally conducted transonic laminar flow research using a pylon mounted beneath an F-104. Fiberset fabricated several nose shapes for this fixture including one with the hyperbolic shape that would meet the laminar flow dimensional requirements and a second shape that would hold the tiles later used to protect the space shuttle on re-entry.

Project Name: F-18 Radome Vortex Control Model

As an example of versatility and ingenuity in saving our customers time and money without lowering our standards of quality and workmanship, consider the F-18 Forebody Vortex Control Project. This was a full-scale wind tunnel model. Instead of the costly process of generating a model of a radome from blueprints, we made the tooling using a lightening struck aircraft nose. Tooling built this way from actual full-sized aircraft insures an accurate representation of shape. The forebody, radome, and vortex control apparatus was then fabricated with this tooling.

Project Name:
F-15 Advanced Flight Test Fixture (AFTF)

Customer: NASA Ames/Dryden

Fiberset was selected to fabricate a new fixture for the F-15 test bed aircraft to replace the old F-104 FTF with a larger and more versatile test fixture called the Advanced Flight Test Fixture. Critical tolerances were required in fabricating a vertical fin portion, a complex elliptical leading edge with pressure orifices that could withstand temperatures up to 250 degrees F, and left-side panels with pressure orifices and tubing. The complete fabrication also included templates for future panel fabrication. Currently the F-15 AFTF is being used for tile erosion tests for the X-33 Advanced Technology Demonstrator for new technologies needed for a Reusable Launch Vehicle (RLV) dubbed the “Venture Star.” For more information on the X-33 program visit http://msfc.nasa.gov.